Mesostructured transition aluminas

ABSTRACT

Mesoporous crystalline alumina compositions and process for the preparation thereof are described. The compositions are useful as catalysts and absorbents.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a divisional of application Ser. No. 09/917,147filed on Jul. 27, 2001 now U.S. Pat. No. 7,090,824.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH DEVELOPMENT

This invention was funded by NSF CHE-9903706. The U.S. Government hascertain rights in this invention.

BACKGROUND OF THE INVENTION

Field of the Invention

The class of aluminum oxide reagents known as “transition aluminas” playcommercially important roles as catalysts or catalyst supports in manychemical processes, including the cracking, hydrocracking andhydrodesulfurization of petroleum, the steam reforming of hydrocarbonfeed stocks ranging from natural gas to heavy naphthas to producehydrogen, the synthesis of ammonia, and the control automobile exhaustemissions, to name a few. Transition aluminas also are used extensivelyas absorbents.

The usefulness of transition aluminas in catalysis and adsorptionprocesses can be traced to a combination of favorable texturalproperties (i.e., relatively high surface areas and porosity) andsurface chemical properties that can be either acidic or basic dependingin part on the transition alumina structure and on the degree ofhydration and hydroxylation of the surface. Structurally, all transitionaluminas are disordered crystalline phases. Although the oxygen atomsare arranged in regularly ordered close packed arrays, the aluminumatoms adopt different ways of occupying the tetrahedral and octahedralinterstacies within the oxygen lattice. Variations in the relativeplacement of aluminum ions in the tetrahedral and octahedral positionsleads to different phases that can be distinguished by NMR techniquesand by x-ray diffraction and other scattering methods. At least sevendifferent transition alumina phases have been described, namely, chi,kappa, rho, eta, gamma, delta, and theta (Wefers, K. and Misra, C.,Oxides and Hydroxides of Aluminum, Alcoa Technical Paper No. 19,Revised, Alcoa Laboratories, 1987).

Transition aluminas are formed through the thermal dehydration anddehydroxylation of aluminum trihydroxides (e.g., gibbsite or bayerite)or aluminum oxyhydroxides (e.g., boehmite, diaspore). Collectively, thehydroxides and oxyhydroxides of aluminum are called aluminum hydrates orhydrated aluminas, although they have very different formulascorresponding to Al(OH)₃ and AlO(OH), respectively. The thermaldehydration of gibbsite can lead to the formation of chi, kappa, rho,eta or theta transition aluminas, depending on the heating rate, thedwell temperature and the atmosphere in contact with the solid phase.The thermal dehydration of boehmite can afford gamma, eta, delta, ortheta phases, depending on the conditions of dehydration and theparticle size and degree of crystallinity of the starting boehmite(Wefers, K. and Misra, C., Oxides and Hydroxides of Aluminum, AlcoaTechnical Paper No. 19, Revised, Alcoa Laboratories, 1987.Pseudoboehmite, a poorly ordered form of boehmite with a small primaryparticle size, is often a preferred precursor to transition aluminas,because it typically affords derivatives with relatively high surfaceareas and pore volumes. Boehmite and pseudoboehmite are useful aluminasin their own right, particularly when they are in high surface areaform. For instance, Rehyrazal™ is a high surface area boehmite that isused extensively as a vaccine adjuvant (www.reheis.com; Gupta, R. K.,Advanced Drug Delivery Reviews, 32 155-172 (1998)).

All transition aluminas will form the structurally stable andcomparatively inert aluminum oxide known as alpha alumina when heated toa temperature above about 1000° C. Because transition aluminas areformed through thermal dehydration processes, they are sometimes called“activated aluminas”. However, the term “transition aluminas” is moreappropriate, because these phases are encountered as intermediates alongthe thermal pathways that transform hydrated aluminas to alpha alumina.

Among the transition aluminas mentioned above, those derived from thethermal dehydration of boehmite and pseudoboehmite, particularly gammaand eta, are often preferred for catalytic and adsorption applications.Gamma alumina is formed from well ordered boehmite at a temperatureabove about 400 to 450° C. depending on the particle size.Pseudoboehmite, a disordered form of boehmite containing an amorphousalumina fraction, can be transformed to eta alumina upon dehydration.Gamma alumina formed from course grained boehmite may be transformed todelta alumina at about 800° C. Both eta and delta aluminas transform totheta alumina at temperatures above about 800-900° C. depending onparticle size. Finally, theta alumina transforms to alpha alumina aboveabout 1000° C.

Recently reported studies indicate that these transition alumina phasescan be mixtures of transition phases with one transition alumina phasebeing dominant. But the purity of the transition alumina phase is notthe limiting factor in determining the performance properties incatalysis and adsorption. Normally, it is the textural properties (i.e.,the pore size, pore volume, and surface area), along with the surfacechemical properties, that determine the performance properties of atransition alumina in catalysis and adsorption. As noted earlier, thephase and hydration state of the surface determines the surfaceproperties. However, the textural properties are determined by thefundamental (primary) particle size of the alumina, as well as theaggregated particle size. By optimizing the textural properties, one mayexpect to greatly improve the performance properties of a transitionalumina derived from boehmite. The surface areas of most commerciallyavailable gamma aluminas, for example, typically have a BET surfacearea<250 m²/g and a pore volume<0.50 cc/g. Thus, there is a need todevelop transition alumina phases with substantially improved texturalproperties in order to achieve improved performance in catalysis andadsorption.

It has been recognized recently that the surface area and porosity of analumina can be substantially increased by forming a mesostructurethrough supramolecular assembly pathways (Bagshaw, S. A.; Pinnavaia, T.J., Angew. Chem. Intern. Ed. Engl. 1996, 35, 1102-1105; Pinnavaia, T.J.; Bagshaw, S. A., U.S. Pat. No. 6,027,706). In this approach asurfactant is used to direct the formation of a mesostructure with wallscomprised of the alumina. Removing the surfactant by solvent extractionor by calcination generated a mesostructured alumina. The formation of amesostructure was indicated by the presence of at least one low anglerefection in the x-ray diffraction patterns of the as madealumina-surfactant composition and the final surfactant-free alumina.The low angle diffraction peak corresponded to a pore to porecorrelation distance of at least 2.0 nm. Several examples of similarmesostructured aluminas have been reported more recently (Davis et al.,Chem. Mater. 1996, 8, 1451; Gabelica et al., Microporous MesoporousMater. 2000, 35-36, 597; Cabrera et al. Adv. Mater. 1999, 11, 379). Forall of these previously reported mesostructured aluminas, however, thewalls of the mesostructure were amorphous. That is, neither the oxygenatoms nor the aluminum atoms were arranged on lattice points, asindicated by the absence of Bragg reflections in the wide angle regionof the diffraction patterns. Consequently, these reported mesostructuredaluminas can be described as being mesostructured alumina gels. Theyhave limited stability under hydrothermal conditions. Also, thesemesostructured aluminas with atomically amorphous framework walls lackedthe desired surface acidity and basicity characteristic of an atomicallyordered transition alumina, thus limiting their usefulness in chemicalcatalysis and adsorption. Thus, there is a need to form mesostructuredforms of transition aluminas with atomically ordered pore walls, as wellas mesostructured forms of hydrated aluminas which serve as precursorsto transitions aluminas.

OBJECTS OF THE INVENTION

It is therefore an object of the present invention to provide transitionaluminas and precursor hydrated aluminas which are mesoporous. It isfurther an object of the present invention to provide a process forproducing such aluminas which is economical and relatively easy toperform. These and other objects will become increasingly apparent byreference to the following description and the drawings.

SUMMARY OF THE INVENTION

The present invention relates to a mesostructured crystalline hydratedalumina composition exhibiting at least one low angle x-ray diffractionline corresponding to a lattice spacing of at least 2.0 nm and multiplewide angle x-ray diffraction lines with CuKα radiation wherein λ is0.1541 nm corresponding to an ordered lattice comprised of oxygen atomsand hydroxide groups with aluminum in interstitial positions within thelattice, wherein the surface area is at least 200 m²/g; and wherein thepore volume is at least 0.40 cm³/g.

The present further relates to a mesostructured crystalline hydratedalumina and organic modifier composite composition wherein thecomposition exhibits at least one low angle x-ray diffraction linecorresponding to a lattice spacing of at least 2.0 nm and multiple wideangle x-ray diffraction lines corresponding to an ordered latticecomprised of oxygen atoms and hydroxide groups with aluminum ininterstitial positions within the lattice.

Further, the present invention relates to a mesostructured crystallinetransition alumina composition:

wherein the composition exhibits at least one low angle x-raydiffraction line corresponding to a lattice spacing of at least 2.0 nmand multiple wide angle x-ray diffraction lines with CuKα radiationwhere λ is 0.1541 nm corresponding to an ordered oxygen atom latticewith aluminum in interstitial positions within the lattice, wherein thesurface area is at least 200 m²/g; and wherein the pore volume is atleast 0.40 cm³/g.

The present invention also relates to a process for the preparation of amesostructured hydrated alumina-organic modifier composite compositionwhich comprises:

(a) reacting an alumina precursor selected from the group consisting ofaluminum salts, oligomeric oxyhydroxyaluminum cations, non-ionicaluminum molecules and mixtures thereof in solution with hydroxide ionsin the presence of an organic modifier at a temperature between 0° and200° C. for a period of time sufficient to cause crystallization; and

(b) filtering, washing and drying the product.

The present invention also relates to a process for the preparation of amesostructured hydrated alumina composition which comprises:

(a) adding a stoichiometric quantity of water to an aluminum alkoxide,optionally in alcohol solution, at a temperature between 0° and about100° C. for a period of time sufficient to cause hydrolysis of thealuminum alkoxide and crystallization of the mesostructured hydratedalumina phase; and

(b) filtering, washing and drying the product in air.

The present invention also relates to a process for the preparation ofthe mesostructured hydrated alumina composition exhibiting at least onelow angle x-ray diffraction line corresponding to a lattice spacing ofat least 2.0 nm and multiple wide angle x-ray diffraction lines withCuKα radiation wherein λ is 0.1541 nm corresponding to an orderedlattice comprised of oxygen atoms and hydroxide groups with aluminum ininterstitial positions within the lattice, wherein the surface area isat least 200 m²/g; and wherein the pore volume is at least 0.40 cm³/g;which comprises treating a mesostructured crystalline hydrated aluminaand organic modifier composite composition, wherein the compositionexhibits at least one narrow angle x-ray diffraction line correspondingto a lattice spacing of at least 2.0 nm and multiple wide angle x-raydiffraction lines corresponding to an ordered lattice comprised ofoxygen atoms and hydroxide groups with aluminum in interstitialpositions within the lattice, so that the organic modifier is removed bysolvent extraction, thermal treatment, or a combination of solventextraction and thermal treatment.

The present invention also relates to a process for the preparation of amesostructured transition alumina composition which exhibits at leastone low angle x-ray diffraction line corresponding to a lattice spacingof at least 2.0 nm and multiple wide angle x-ray diffraction lines withCuKα radiation where λ is 0.1541 nm corresponding to an ordered oxygenatom lattice with aluminum in interstitial positions within the lattice;wherein the surface area is at least 200 m²/g; wherein the pore volumeis at least 0.40 cm³/g;

which comprises heating a mesostructured crystalline hydrated aluminacomposition exhibiting at least one low angle x-ray diffraction linecorresponding to a lattice spacing of at least 2.0 nm and multiple wideangle x-ray diffraction lines with CuKα radiation wherein λ is 0.1541nm, corresponding to an ordered lattice comprised of oxygen atoms andhydroxide groups with aluminum in interstitial positions within thelattice to a temperature in the range 400 to about 900° C. for a periodof time to cause dehydration of the hydrated alumina and the formationof the mesostructured form of the transition alumina.

The present invention also relates to a process for the formation of amesostructured transition alumina composition:

wherein the composition exhibits at least one low angle x-raydiffraction line corresponding to a lattice spacing of at least 2.0 nmand multiple wide angle x-ray diffraction lines with CuKα radiationwhere λ is 0.1541 nm corresponding to an ordered oxygen atom latticewith aluminum in interstitial positions within the lattice;

wherein the surface area is at least 200 m²/g; and

wherein the pore volume is at least 0.40 cm³/g which comprises treatinga mesostructured crystalline hydrated alumina and organic modifiercomposite composition, wherein the composition exhibits at least one lowangle x-ray diffraction line corresponding to a lattice spacing of atleast 2.0 nm and multiple wide angle x-ray diffraction linescorresponding to an ordered lattice comprised of oxygen atoms andhydroxide groups with aluminum in interstitial positions within thelattice; a to a temperature in the range 400 to about 900° C. for aperiod of time to cause removal of the organic modifier component,dehydration of the hydrated alumina component, and the formation of themesostructured form of the transition alumina.

The present invention relates to a process for converting a first liquidor gas stream to a second liquid or gas stream using a catalyst, theimprovement in which comprises:

using as the catalyst or catalyst component an alumina compositionselected from the group consisting of

(a) a mesostructured crystalline hydrated alumina composition exhibitingat least one low angle x-ray diffraction line corresponding to a latticespacing of at least 2.0 nm and multiple wide angle x-ray diffractionlines with CuKα radiation wherein λ is 0.1541 nm corresponding to anordered lattice comprised of oxygen atoms and hydroxide groups withaluminum in interstitial positions within the lattice, wherein thesurface area is at least 200 m²/g; and wherein the pore volume is atleast 0.40 cm³/g;

(b) a mesostructured crystalline hydrated alumina and organic modifiercomposite composition wherein the composition exhibits at least onenarrow angle x-ray diffraction line corresponding to a lattice spacingof at least 2.0 nm and multiple wide angle x-ray diffraction linescorresponding to an ordered lattice comprised of oxygen atoms andhydroxide groups with aluminum in interstitial positions within thelattice; and

(c) a mesostructured crystalline transition alumina composition: whereinthe composition exhibits at least one low angle x-ray diffraction linecorresponding to a lattice spacing of at least 2.0 nm and multiple wideangle x-ray diffraction lines with CuKα radiation where λ is 0.1541 nmcorresponding to an ordered oxygen atom lattice with aluminum ininterstitial positions within the lattice, wherein the surface area isat least 200 m²/g; and wherein the pore volume is at least 0.40 cm³/g.

Finally, the present invention relates to the process for adsorbing acomponent from a gas or liquid stream, the improvement which comprisesusing as an adsorbent or adsorbent component an alumina compositionselected from the group consisting of

(a) a mesostructured crystalline hydrated alumina composition exhibitingat least one low angle x-ray diffraction line corresponding to a latticespacing of at least 2.0 nm and multiple wide angle x-ray diffractionlines with CuKα radiation wherein λ is 0.1541 nm corresponding to anordered lattice comprised of oxygen atoms and hydroxide groups withaluminum in interstitial positions within the lattice, wherein thesurface area is at least 200 m²/g; and wherein the pore volume is atleast 0.40 cm³/g;

(b) a mesostructured crystalline hydrated alumina and organic modifiercomposite composition wherein the composition exhibits at least onenarrow angle x-ray diffraction line corresponding to a lattice spacingof at least 2.0 nm and multiple wide angle x-ray diffraction linescorresponding to an ordered lattice comprised of oxygen atoms andhydroxide groups with aluminum in interstitial positions within thelattice; and

(c) a mesostructured crystalline transition alumina composition: whereinthe composition exhibits at least one low angle x-ray diffraction linecorresponding to a lattice spacing of at least 2.0 nm and multiple wideangle x-ray diffraction lines with CuKα radiation where λ is 0.1541 nmcorresponding to an ordered oxygen atom lattice with aluminum ininterstitial positions within the lattice, wherein the surface area isat least 200 m²/g; and wherein the pore volume is at least 0.40 cm³/g.

BRIEF DESCRIPTION OF FIGURES

FIG. 1 shows small angle XRD patterns of MSU-S/B and MSU-γmesostructures assembled from Al₁₃ oligocations and nonionic PluronicP84 surfactant according to Example 3.

FIG. 2 shows wide angle XRD patterns of MSU-S/B and MSU-γ mesostructuresassembled according to Example 3; diffraction lines assigned to boehmiteare marked “B” and those assigned to ammonium chloride as a by-productare marked “C”.

FIG. 3 shows TEM image of mesoporous MSU-γ alumina prepared according toExample 3.

FIG. 4 shows small angle XRD patterns of MSU-S/B and MSU-γmesostructures assembled from Al₁₃ oligocations as the aluminum sourceand tallow tetra-amine as the structure director as described in Example9.

FIG. 5 shows wide-angle XRD patterns of MSU-B (as-made) and MSU-Y(calcined) assembled from Al₁₃ with Tallow tetra-amine as described inExample 9. The reflections marked with “B” are attributable to theBoehmite phase comprising the framework walls.

FIG. 6A shows N₂ adsorption-desorption isotherms for the MSU-γ aluminaprepared according to the method of Example 9.

FIG. 6B shows BJH pore size distribution determined from the adsorptionfor the MSU-γ alumina prepared according to Example 9.

FIG. 7A shows low angle x-ray diffraction patterns of as-mademesostructured MSU-S/B surfactant/boehmite mesostructure prepared fromP84 surfactant as the structure director and mesostructured MSU-γalumina obtained by calcining the as-made MSU-S/B at 500° C. accordingto Example 16.

FIG. 7B shows wide angle x-ray diffraction pattern of as-mademesostructured MSU-S/B surfactant/boehmite mesostructure prepared fromP84 surfactant as the structure director and mesostructured MSU-γalumina obtained by calcining the as-made MSU-S/B at 500° C. accordingto Example 16.

FIG. 8A shows nitrogen adsorption isotherm for MSU-γ alumina obtainedaccording to Example 16.

FIG. 8B shows BJH adsorption pore size distribution for MSU-γ aluminaobtained according to Example 16.

FIG. 9 shows TEM images of MSU-γ alumina prepared from an aluminumalkoxide and a PEO surfactant according to Example 16 on differentscales.

FIG. 10A shows low angle powder x-ray diffraction pattern of MSU-γalumina prepared in absence of surfactant according to Example 20.

FIG. 10B shows wide angle powder x-ray diffraction pattern of MSU-γalumina prepared in the absence of surfactant according to Example 20.

DESCRIPTION OF PREFERRED EMBODIMENTS

The present invention describes compositions of matter that comprisemesostructured forms of transition aluminas. This invention alsodiscloses mesostructured forms of hydrated aluminas, particularlymesostructured boehmite, which is a valuable precursor to severalmesostructured transition aluminas. The textural properties of thesecompositions are generally superior and more useful in catalytic andadsorption applications in comparison to bulk transition aluminas orbulk hydrated aluminas that lack a mesostructured framework. Themesostructured forms of transition aluminas are derived in part from thethermal treatment of mesostructured hydrated alumina-organic modifiercomposite compositions. Depending on the thermal processing conditionsused for the removal of the organic modifier and the dehydration of thehydrated alumina phase, mesostructured forms of hydrated aluminas andtransition aluminas are formed that are free of the organic modifier andsuitable for improved use in adsorption and catalytic applications.

DESCRIPTION OF THE INVENTION

The first embodiment of this invention is directed toward thepreparation of a mesostructured hydrated alumina phase. In particular,we disclose the preparation of mesostructured forms of boehmite, whichare denoted as MSU-S/B aluminas. Evidence for a mesostructured boehmitephase is provided by the presence of at least one x-ray diffraction linein the low angle region corresponding to a lattice spacing of at least2.0 nm. In addition, the diffraction patterns of the said mesostructuredboehmites exhibit wide angle reflections characteristic of a bulk,atomically ordered boehmite phase. This combination of low angle andwide angle x-ray reflections is unique among boehmite phases. The lowangle reflection is indicative of a network that is ordered on amesoscopic length scale (i.e., 2.0-50 nm), whereas the wide anglereflections show that the particles comprising the mesoscopic networkcontain an atomically ordered boehmite phase.

The ordered mesoscopic network of an MSU-B boehmite contains pores, thesize of which is correlated with the lattice spacing for the low anglediffraction peak. However, the mesostructured pores are not the onlypores present in these mesostructured boehmite compositions. In additionto the mesostructured pores, there are textural pores. Textural poresare defined here as intra- and interparticle pores that are notsufficiently ordered to give rise to a x-ray diffraction peak. Thetextural pores have a relatively broad distribution that typicallyoverlaps the pore distribution associated with the mesostructurednetwork. Thus, the actual pore size distribution, as determined from theadsorption or desorption branches of the nitrogen adsorption-desorptionisotherms, typically exceeds the lattice spacing of the mesostructuredboehmite network. Nevertheless, the pores associated with themesostructured network are very desirable in practical applicationsinvolving adsorption and reactivity, because they contribute to theoverall surface area and pore volume of the boehmite. For instance, amesostructured boehmite is expected to be a much more potent vaccineadjunct than a conventional boehmite due to its higher surface area andpore volume.

In general, as the length scale of a mesostructured MSU-B boehmitenetwork increases, the average size of the overall pore distributionalso increases. It is not possible, however, to quantitativelydistinguish between the pores originating from the ordered mesoscopicnetwork indicated by the low angle x-ray reflection and thoseoriginating from a particle texture that does not have an x-raydiffraction signature. In general, mesostructured boehmite compositionswith the largest network length scale are preferred, because the overallsurface area and pore volume typically as measured by nitrogenadsorption increases with increasing network pore-pore correlationdistance as measured by low angle x-ray diffraction.

The mesostructured boehmite compositions of this invention are preparedby one of two general methods. The first method utilizes the hydrolysisof an aluminum alkoxide as a means of controlling the growth of primaryboehmite particles that intergrow to form a mesostructured network ofparticles and pores that give rise to a low angle x-ray diffractionline. Although the hydrolysis of aluminum alkoxides has been usedextensively to form boehmite and pseudoboehmite compositions previously(Industrial Alumina Chemicals, C. Misra, ACS Monograph 184 ACS,Washington, D.C. p. 48 (1986)), the possibility of formingmesostructured boehmites through this pathway has gone unrecognized.However, the alkoxide hydrolysis pathway is sensitive to the sequence ofaddition of the reagents, as well as to the reaction stoichiometry. Forthis reason, the pathway is generally difficult to implementreproducibly and is less preferred.

The more preferred method of preparation of a mesostructured MSU-Bboehmite is through the condensation polymerization reaction of analumina precursor in the presence of a non-ionic amine or non-ionicpolyethylene oxide modifier. The presence of the modifier controls thegrowth of primary boehmite particles and regulates the intergrowth andaggregation of the particle. Therefore, the size of the mesostructurednetwork pores and textural pores are regulated by the amine and PEOmodifier. Amine and PEO modifiers with surfactant properties arepreferred modifiers, in part, because they not only regulate the growthof the primary particles and texture of the intergrown and aggregatedparticles, but they also occupy space and enlarge the size of themesostructured pores and textural pores present in the boehmite. Also,the use of a non-ionic modifier allows a variety of precursors to beused as an alumina source, many of which are less costly than aluminumalkoxides. Thus, the organic modifier route to the mesostructuredboehmite compositions of this invention are preferred.

The organic amine and PEO modifiers are removed from the mesostructuredboehmite composition by thermal evaporation or thermal decomposition ata temperature below the transition temperature of the boehmite(typically less than about 400° C.). Alternatively, the modifier can beremoved by solvent extraction or by a combination of solvent extractionand thermal evaporation/decomposition. The open pore structure madeavailable through the removal of the organic modifier can then be usedto accommodate other guest molecules for applications in adsorption andchemical conversions.

The second principal embodiment of this invention is directed atmesostructured forms of transition aluminas. The structural propertiesof these compositions parallel those described above for mesostructuredboehmite, except that the aluminum oxide comprising the mesostructurednetwork is an atomically ordered transition alumina. Thus, themesostructured transition aluminas of this invention exhibit a low anglex-ray diffraction peak corresponding to a lattice spacing of at least2.0 nm and wide angle diffraction peaks characteristic of an atomicallyordered transition alumina. These mesostructured transition aluminashave surface areas and pore volumes that are substantially larger thanconventional transition aluminas. For example, commercial grades oftransition aluminas have only textural porosity and lack the orderedmesoscopic network structure of the present convention. Typical surfaceareas and pore volumes for these commercial grades of transitionaluminas, including the most commonly used gamma-alumina, are in therange 200-250 m²/g and 0.35-0.50 cm³/g. In contrast, the mesostructuredtransition aluminas of this invention, which we denote as MSU-γ,typically have surface areas beyond the 200-250 cm³/g range and poresizes well beyond 0.50 cm³/g. These large surface areas and pore volumesmake the mesostructured MSU-γ alumina and other transition aluminas ofthis invention particularly attractive as catalysts and catalystsupport. Gamma-alumina, for instance, is widely used as a catalystcomponent in petroleum refining. This oxide, in combination with clay,meta-kaolin, zeolites, and other oxides, comprises an important activeingredient in commercial petroleum cracking catalysts. Themesostructured gamma-alumina of this invention is expected to be an evenbetter petroleum refining catalyst component, owing primarily to thehigher available surface areas and pore volumes. In addition to being animproved ingredient for the fluidized catalytic cracking andhydrocracking of petroleum, the mesostructured transition aluminas ofthis invention also should be useful catalyst components for many otherchemical conversions, including the hydrodesulfurization of petroleum,the steam reforming of hydrocarbons, ammonia synthesis, and many otherheterogeneous catalytic processes.

The mesostructured transition aluminas of this invention are formed fromthe thermal dehydration of hydrated aluminas that have been prepared inthe presence of non-ionic organic modifiers. In one of the preferredforms of the invention, the hydrated alumina is a boehmite that has beencrystallized in the presence of a non-ionic amine, alcohol, orpolyethylene oxide (PEO) modifier. The resulting boehmite-organicmodifier composite composition, which we denote in general as a MSU-S/Balumina, is then heated to a temperature above about 400° C. to removethe organic modifier and to transform the hydrated alumina component toa mesostructured gamma-alumina, which we denote here as MSU-γ-alumina.It is further preferred that the amine and PEO modifier is a surfactant,which helps to improve the pore volume of the final mesostructuredtransition alumina. It is yet further preferred that the initialhydrated alumina-organic modifier composition is mesostructured, thoughthis is not essential. Even MSU-S/B boehmite-modifier compositecompositions that are not mesostructured (as evidenced by the lack of alow angle XRD peak) can be transformed into a mesostructured transitionalumina. We presume that although the initial hydrated alumina-organicmodifier composition is not mesostructured, such compositions apparentlycan become mesostructured during the thermal treatment process leadingto the formation of the mesostructured transition alumina. Nevertheless,having the initial hydrated alumina-modifier composite in mesostructuredform is highly preferred.

This disclosed approach to mesostructured transition aluminas is notrestricted to the use of boehmite as the hydrated alumina component inthe initial hydrated alumina-organic modifier composition. Those skilledin the art of alumina chemistry will know that other forms of hydratedaluminas can be thermally dehydrated to transition aluminas. Thus,possible alternatives to boehmite in the initial hydratedalumina-organic modifier precursor include diaspore, gibbsite, andbayerite. Also, it is known that one transition alumina phase can betransformed into another transition alumina under suitable processingconditions. Thus, the teaching of this invention should apply as well tothe preparation of other mesostructured transition alumina phases,including delta, theta, chi, rho, eta, kappa, as well as gamma.

The mesostructured alumina compositions of this invention can be formedfrom a variety of precursors. Suitable precursors include the followinggeneral groups of aluminum compounds:

-   -   ionic aluminum salts containing hydrated aluminum cations, such        as aluminum trichloride hexahydrate, aluminum trinitrate        nonahydrate, and the hydrolyzed aluminum cations of these salts        when they are dissolved in aqueous solution (for example,        hydrated Al(OH) (H₂O)₅ ²⁺ and Al₂(OH)₂(H₂O)₈ ⁴⁺ cations)    -   non-ionic aluminum-containing molecular composition, such as an        aluminum alkoxides, anhydrous aluminum halides, aluminum        beta-diketonates and the like.    -   Oligomeric aluminum cations, such as the cation comprising        aluminum chlorhydrate, Al₁₃O₄(OH)₂₄(H₂O)₁₂ ⁷⁺, the related Al₃₀        cationic oligomer, and like ions of higher aluminum nuclearity        (J. Rowsell, and L. F. Nazar, J. Am. Chem. Soc.,        2000 (122) 3777. L. Allouche, G. Gerardin, T. Loiseau, G. Ferey,        and F. Taulelle, Angew. Chem. Int. Ed. 2000, 39 (3) 511).    -   Oligomeric oxyhydroxycations of aluminum formed by reaction of        mixtures of aluminum cations in solution and finely divided        aluminum metal.

The preferred organic modifiers used in forming the mesostructuredalumina compositions of this invention are nonionic surfactants selectedfrom the groups comprising nonionic surfactants wherein the hydrophilicsegment of the surfactant is a polyethylene oxide block and non-ionicalkylene amine, alkylene polyamine, and polypropylene oxide aminesurfactants. Also, preferred are non-ionic amine modifiers, especiallyalkylene amines; an alkylene polyamines, an polypropylene oxide amine,and polypropylene oxide polyamines, particularly those that exhibitsurfactant properties.

EXAMPLES

In the Examples provided below, the synthesis and properties of themesostructured boehmite and gamma-alumina phases of this invention isdemonstrated. The as-synthesized MSU-B and MSU-S/B and calcinedMSU-γ-compositions were characterized by X-ray diffraction (XRD) using aRigaku Rotaflex equipped with Cu-Kα radiation; λ=0.1541 nm). Thepresence of a low angle diffraction peaks corresponding to average poreto pore correlation lengths of at least 2.0 nm was indicative of ahierarchical mesostructure. Wide angle XRD reflections were used toindicate the presence of atomically ordered walls of boehmite or atransition alumina.

Nitrogen BET surface areas, pore volumes and framework pore sizes weredetermined using nitrogen adsorption-desorption methods. The sorptometerused to record the adsorption-desorption isotherms was a MicromeriticsASAP 2010 and Tristar instruments. The samples for adsorptionmeasurement were degassed at 150° C. and <10⁻⁵ torr for 12 h beforemeasurement. In defining the pore size distribution we applied the BJHmodel to both the adsorption and desorption isotherms in order tocharacterized the framework pore structure. Owing to the presence of ahysterisis loop for all samples, the adsorption isotherm always provideda higher value of the average pore size. In characterizing thecompositions of the present invention we report both pore sizes.

Particle textures were examined by Transmission Electron Microscopy(TEM) using a JEOL 100 CX2 electron microscope.

Examples 1-3

These Examples illustrate the use of the following non-ionic organicmodifiers for the preparation of mesostructured surfactant-boehmitecomposite compositions (denoted MSU-S/B) using aluminum chlorohydrate,[Al₁₃O₄(OH)₂₄ (H₂O)₁₂]Cl₇ as the aluminum source

-   -   Example 1: Pluronic L64 (BASF, EO₁₃PO₃₀EO₁₃)    -   Example 2: Pluronic P65 (BASF, EO₁₉PO₃₀EO₁₉),    -   Example 3: Pluronic P84 (BASF, EO₁₉PO₄₃EO₁₉),        Each modifier is a polyethylene oxide (PEO)/polypropylene oxide        (PPO) tri-block co-polymer surfactant. The aluminum        chlorohydrate was supplied by Rehies, Inc. as a 12.4 wt % Al        solution. The resulting composite mesostructures were        subsequently converted through calcination to surfactant-free        mesostructured transition aluminas with gamma alumina framework        walls (denoted MSU-γ).

In a typical synthesis 21.78 g of the Al₁₃ oligomer solution (0.10 molAl) was mixed with 4.35 g (1.5 mmol) of L64, or 4.2 g (1.2 mmol) of P65,or 4.2 g (1.0 mmol) of P84 surfactant in a Waring blender for ca. 5 min.The resulting mixtures were aged at 25-45° C. for 24 h till a clear solwas formed. The temperature of the mixtures was then elevated to 70° C.for a period of 6 h. Then 3.02 g (0.05 mol) of concentrated NH₄OHsolution (28 wt % NH₃) was introduced under gentle agitation to give afinal overall Al/OH⁻ ratio of 1:3. The resulting gels were allowed toage in closed glass reaction vessels at 70° C. for an additional 6 h andthen at 100° C. for 24 h. The as-synthesized MSU-S/B composites wereair-dried. The XRD powder patterns of each product exhibited low anglediffraction peaks indicative of a wormhole mesostructure withcrystalline Boehmite walls and ammonium chloride as a by-product (seebelow).

The air-dried MSU-S/B products of Examples 1-3 were calcined in air at325° C. for 3 h and then at 550° C. for 4 h to completely remove thesurfactant and the ammonium chloride by-product and to form asurfactant-free mesostructured MSU-γ-alumina with atomically orderedwalls. The ramp rate used to achieve the calcination temperatures was 2°C./min. As illustrated by the diffraction pattern given in FIG. 1, theas-made MSU-S/B composites exhibited a well-defined basal reflectionpeak in the small angle region 0.5-10 (2θ) degrees, indicating theperiodicity of the mesostructured pores. In the wide angle region from10 to 80 degrees two-theta, the as-made products gave diffraction lineswith lattice spacings and relative intensities characteristic ofBoehmite (JCPDS Card #21-1307) and α-NH₄Cl (JCPDS Card # 34-0710) as aby-product. The absence of reflections characteristic of the startingreagents indicated that the hydroxylation reaction to form MSU-S/B wascompleted. Upon calcination of the MSU-S/B products, the mesostructuredMSU-γ phases were formed which exhibited wide angle XRD lines consistentwith gamma alumina framework walls (JCPDS Card #10-0425). TEM images(FIG. 3) indicated a lamellar framework motif with a slit-like frameworkpores. The structural properties of these MSU-γ products are summarizedin Table 1. It can be seen that the pore size of resulting MSU-γ phaseincreased with increasing surfactant size.

Examples 4-5

These Examples illustrate the use of non-ionic surfactant TergitolT15-S-12 with the formula C₁₅H₃₁(OC₂H₄)₁₂OH (Example 4), and TergitolT15-S-20 with the formula C₁₅H₃₁(OC₂H₄)₂₀OH (Example 5) as structuredirectors for the assembly of mesostructured MSU-S/B and MSU-γcompositions from aluminum chlorhydrate, [Al₁₃O₄(OH)₂₄(H₂O)₁₂]Cl₇, asthe aluminum source. The procedure is analogous to that of Examples 1-3,but the surfactant was replaced by the Tergitol surfactants. The molarcompositions of the final reaction mixtures were:

-   -   21.78 g (100 mmol Al) of Al₁₃ solution (Reheis, 12.4 mass % Al)    -   8.3 g (1.1 mmol) T15-S-12 in Example 4 or T15-S-20 (0.75 mmol)        in Example 5    -   3.02 g (50 mmol) NH₄OH as concentrated solution (28 wt % NH₃)

The XRD patterns of the corresponding as-synthesized MSU-S/B andcalcined MSU-γ mesostructures resemble those depicted in FIG. 1 and FIG.2. The physical properties of the mesostructured products obtained fromthese two examples are summarized in Table 1.

Example 6

This Example illustrates the synthesis of mesostructured MSU-S/B andMSU-γ compositions alumina from aluminum nitrate as the aluminum sourceand the non-ionic block co-polymer Pluronic P84 as the structuredirector. A 37.5 g (0.1 mol) quantity of Al(NO₃)₃9H₂O was dissolved in16 g (1 mol) of deionized water then mixed with 6.3 g (1.5 mmol) ofPluronic P84 in a blender for 5 min. The resultant mixture was aged at35-65° C. for 24 h till a clear sol was formed. The temperature of thesol was elevated to 70° C. for a period of 6 h and then 21.8 g ofconcentrated NH₄OH solution (0.36 mol NH₄OH) was introduced under gentleagitation. The final molar composition of reactants was1Al:0.02P84:3.6NH₄OH. The resulting gel was kept in a closed glassreaction vessel at 70° C. for 6 h, then at 100° C. for 24 h, forming aMSU-S/B mesophase. The XRD pattern indicated the presence of amesostructure with boehmite walls and the presence of an ammoniumnitrate by-product (JCPDS Card #47-0867). The as-synthesized compositewas air-dried and calcined in air at 220° C. for 3 h, then at 550° C.for 4 h, using a ramp speed of 2° C./min to reach the indicated dwelltemperatures. This heat treatment removed the surfactant and sublimedaway the ammonium nitrate by-product, affording a surfactant-free MSU-γmesostructure. The properties of the relevant mesophases obtained fromthis example are summarized in Table 1.

Example 7

This example describes the assembly of mesostructured aluminacompositions from aluminum chloride as the aluminum source and thenon-ionic block co-polymer Pluronic P84 as the structure director. In atypical synthesis 24.1 g (0.1 mol) of AlCl₃.6H₂O was dissolved in 18 g(1 mol) of deionized water and then the solution was mixed with 8.4 g(1.5 mmol) of Pluronic P84 in a blender for 5 min. the mixture washeated at 70° C. and for 6 h and then 21.8 g (0.05 mol NH₄OH) ofconcentrated NH₄OH solution was introduced under gentle agitation. Thefinal composition of reactants was 1Al:0.02P84:3.6NH₄OH. The resultinggel was heated an additional at 6 h at 70° C., then at 100° C. for 24 h,to obtain the MSU-S/B surfactant/boehmite mesostructure. Theas-synthesized composite was air-dried and converted to mesostructuredMSU-γ-alumina by calcination in air at 325° C. for 3 h, then at 550° C.for 4 h using a ramp speed of 2° C./min. A mesostructured MSU-γ-aluminawas obtained by the conversion of MSU-B mesophase. The powder XRDpatterns of these MSU-S/B and MSU-γ samples were analogous to thosedepicted in FIG. 1 and FIG. 2. The properties of the mesostructuresprepared in this example are summarized in Table 1.

Example 8

This example illustrates the synthesis of mesostructured aluminacompositions using as an aluminum source a solution of oligocationsformed by the reaction of aluminum chloride and aluminum powder andPluronic P84 as the structure director. In a typical synthesis 4.1 g ofAlCl₃.6H₂O solution (0.017 mol) was dissolved 20 g de-ionized water, andthen 2.3 g (0.085 mol) of aluminum powder was suspended in the solutionat 80° C. for 8 h. The solid remaining in the suspension (ca. 0.05 g)was filtrated out and the liquid obtained was combined with 4.2 g (1mmol) of Pluronic P84 in a blender for ca. 5 min, then the resultantmixture was aged at 25-45° C. for 24 h. The temperature of the resultantsol was elevated to 80° C. for 6 h and then 3.02 g of concentrated NH₄OHsolution (0.05 mol NH₄OH) was introduced under gentle agitation. Thefinal composition of reactants was 1Al:0.01P84:0.5NH₄OH. After keepingthe resulting gel at 80° C. for 6 h, then at 100° C. for 24 h, weobtained a MSU-S/B surfactant/boehmite mesostructure. After air-dryingand calcination of the as-synthesized composite mesostructure in air at325 for 3 h, then at 550° C. for 4 h, using a ramp speed of 2° C./min, amesostructured MSU-γ alumina was obtained. Table 1 provides the physicalproperties of the mesostructured products of this example.

Example 9

This example illustrates the assembly of mesostructured alumina MSU-S/Band MSU-γ from Al₁₃ with tallow tetra-amine (TTeA) as thestructure-directing agent. A 10.3 g (12.5 mmol) quantity of TTeA wasdissolved in 100 ml 70% ethanol solution by volume at 50° C. Then 21.8 gof Al₁₃ solution (0.1 mol Al) was introduced. After allowing theresultant gel to age under isothermal conditions for 24 h, then at 100°C. for 24 h, the solids were separated by filtration and air-dried togive a MSU-S/B hybrid mesostructure. The MSU-S/B was calcined at 320° C.for 4 h, then at 550° C. for 4 h, using a ramp speed of 1° C./min toform the pure alumina MSU-γ mesostructure phase. The XRD patterns of theMSU-S/B and MSU-γ mesostructures in the small and wide-angle regions aredepicted in FIG. 4 and FIG. 5, respectively. The nitrogenadsorption-desorption isotherms and the BJH pore size distribution curvefor the MSU-γ mesostructure are described in FIG. 6A and FIG. 6B.

Example 10

This example illustrates the preparation of mesostructured MSU-S/B andMSU-γ mesostructures from Al₁₃ oligocations and dodecylamine (DDA) asthe structure director. In a typical synthesis 4.625 g (0.025 mol) ofDDA was dissolved in 40 ml of ethanol and 11.89 g (0.05 mol Al) aluminumchlorhydrate solution (Reheis) was diluted with 60 ml de-ionized water.Then the DDA solution was added dropwise into the Al₁₃ solution undervigorous stirring. The resultant gel was aged at 35° C. for 24 h, thenat 100° C. for 24 h. The solid thus derived was filtered and air-driedto yield a mesostructures MSU-S/B surfactant/boehmite phase. Calcinationof the hybrid phase at 550° C. for 4 h gave mesostructured MSU-γalumina. Physical properties are given in Table 1.

Comparative Examples 11-13

These examples illustrate the syntheses of conventional boehmites andgamma aluminas from Al₁₃ oligocations (Example 11), AlCl₃ (Example 12),and Al(NO₃)₃ (Example 13) as aluminum sources, but in the absence ofsurfactant.

In the synthesis using Al₁₃, 21.8 g of aluminum chlorhydrate solution(0.10 mol Al) was directly hydrolyzed with 3.02 g (0.05 mol) NH₄OH at70° C. The resultant solids were treated by following procedure asdescribed in Example 4 to give conventional boehmite and gamma aluminacompositions.

The syntheses of condensed boehmite and gamma alumina from Al(NO₃)₃, andAlCl₃ were also conducted by direct hydrolysis of these salts followingthe procedures described in Example 6 and Example 7, respectively, butleaving out the surfactant.

The XRD patterns of boehmite and gamma-alumina prepared from Al₁₃,Al(NO₃)₃, AlCl₃ in the wide-angle region 10-80 (2θ) degrees resembledthose for mesostructured alumina prepared in the presence of thesurfactant. In contrast, the condensed phases did not exhibitreflections attributable to the presence of mesostructure in the smallangle region between 0.5-10 (2θ) degrees.

The textural properties of the condensed gamma alumina phases preparedin the above examples are summarized in Table 1. It is noteworthy thatthe surface areas and pore volumes of these conventional gamma aluminasare substantially smaller than the mesostructured analogs described inthe previous examples.

Comparative Examples 14-15

This comparative example provides the textural properties ofconventional gamma aluminas prepared by the thermal dehydration of twocommercial forms of boehmite, namely, Dispal 18N4-80 alumina powder(Example 14) and Catapal A alumina (Example 15). Both grades of boehmitewere supplied by Vista Chemical Co. of Houston, Tex. The Dispal samplewas calcined in air at 325° C. for 3 h and then at 550° C. for 4 h,whereas the Catapal sample was dehydrated at 500° C. for 4 h. Neithermesoporous gamma alumina exhibited a small angle X-ray diffraction peak.This result is consistent with the absence of a mesostructure.

The textural properties of the gamma aluminas derived from theconventional boehmite are given in Table 1 for comparison with thevalues obtained for the mesostructured transition aluminas embodied inthis invention. Note that the surface area and pore volume for the gammaalumina formed from Dispal are substantially smaller than the valuesobtained for the mesostructured gamma-aluminas of Examples 1-10. Thetransition alumina formed from Catapal A exhibits a somewhat largersurface area and pore volume, but still generally lower than the valuesobserved for the mesostructured gamma aluminas of this invention.

TABLE 1 Properties of alumina compositions MSU- MSU-Gamma A1: Surf: S/BPore Pore. OH d₁₀₀/ d₁₀₀/ S_(BET)/ Vol./ Size^(a)/ Example PrecursorSurfactant Molar ratios nm nm m²g⁻¹ cm³g⁻¹ nm 1 A₁ L64: EO₁₃PO₃₀EO131:0.015:0.5 3.8 5.1 307 0.53 5.8/4.4 2 Al₁₃ P65: EO₁₉PO₃₀EO191:0.012:0.5 3.9 5.7 266 0.59 5.9/4.6 3 Al₁₃ P84: EO₁₉PO₄₃EO191:0.010:0.5 4.4 6.6 299 0.73 8.0/6.4 4 Al₁₃ TS15: 1:0.11:0.5 4.9 6.8 2630.83 9.1/7.2 C₁₅H₃₁(OC₂H₄)₁₅OH 5 Al₁₃ TS20: 1:0.075:0.5 6.3 8.0 248 0.8210.5/8.2  C₁₅H₃₁(OC₂H₄)₂₀OH 6 Al(NO₃)₃ P84: EO₁₉PO₄₃EO19 1:0.02:3.6 3.35.3 302 0.59 6.0/5.0 7 AlCl₃ P84: EO₁₉PO₄₃EO19 1:0.02:3.6 3.8 6.5 3110.69 8.2/6.3 8 AlCl₃/Al P84: EO₁₉PO₄₃EO19 1:0.010:0.5 4.5 9.4 298 0.789.6/7.1 9 Al₁₃ Tallow tetra-amine: 1:0.125:0 8.1 n.d. 369 0.47 4.2/4.0C¹⁴⁻¹⁶NH(C₃H₆NH)₃H 10 Al₁₃ DDA: C₁₂H₂₅NH₂ 5.8 5.5 231 0.36 4.0/—   11Al₁₃ None 1:0:0.5 — — 190 0.25 n.d. 12 AlCl₃ None 1:0:3.6 — — 222 0.25n.d. 13 Al(NO₃)₃ None 1:0:3.6 — — 55 0.13 n.d. 14 Dispal — — — — 1490.42 12.5/7.5  15 Catapal A — — — — 240 0.43 7.5/5.8 ^(a)Mean frameworkpore sizes were calculated from the adsorption/desorption branches ofthe nitrogen adsorption-desorption isotherms, respectively, by using theBJH model.

Example 16

This example illustrates the formation of an as-made MSU-S/Bsurfactant/boehmite mesostructure and a mesostructured MSU-γ transitionalumina from aluminum sec-butoxide, Al(OCH(CH₃)CH₂CH₃)₃, as the aluminumprecursor and a non-ionic tri-block copolymer, (BASF Pluronic 84) as thestructure director. Pluronic 84, herein denoted P84, has the structure(EO)₁₉(PO)₃₉(EO)₁₉, where EO and PO correspond to ethylene oxide andpropylene oxide units, respectively.

The reagents used in the synthesis were aluminum sec-butoxide, P84,water, and 2-butanol. They were combined in the following molar ratios:

1.0 mole Al(OCH(CH₃)CH₂CH₃)₃ 0.015 mole P84 8.16 mole water 0.40 mole2-butanolTo obtain mesostructured MSU-S/B, the aluminum alkoxide, P84, and2-butanol were thoroughly mixed in a blender until homogenous. Theresulting viscous solution was transferred to a glass jar where thespecified amount of water was slowly added with gentle agitation with aspatula in order to achieve thorough mixing and complete hydrolysis ofthe alkoxide. The jar was sealed with Teflon tape, capped, and placed inan oven at 100° C. for 24 hr. The resulting gel was air-dried. The XRDpattern of the dried MSU-S/B indicated a mesostructured aluminum oxidehydroxide with a mesopore correlation distance of 6.5 nm (FIG. 7A) andmultiple wide angle peaks indicative of crystalline boehmite walls (FIG.7B).

To obtain a mesostructured MSU-γ transition alumina, the MSU-S/B samplewas heated was at 2° C./min to 100° C. and held at this temperature for6 hr. Then the temperature was raised at 2° C./min to 300° C. and heldconstant for 3 hr. Finally, the temperature was increased at 2° C./minto 500° C. and maintained at this temperature for 2 hr to completelyremove the template. The low angle XRD pattern of the calcined productcontained a diffraction peak corresponding to a pore to pore correlationdistance of 6.9 nm (FIG. 7A).

The low angle patterns verify the presence of a mesostructure for bothmaterials and the wide angle patterns indicate the presence ofatomically ordered (crystalline) walls comprised of a transitionalumina. The d-spacings that correspond to the peaks in these widepatterns are compared in Table 2 with those provided in the literaturefor boehmite and gamma alumina.

The nitrogen absorption isotherm for the MSU-γ product obtained inExample 16 is given in FIG. 8A. The filling of pores occurs at arelative pressure of 0.75-0.95. This material has a large pore volume of1.15 cc/g and a BET surface area of 306 m²/g. The pore size distribution(BJH-adsorption branch) is centered at approximately 20 nm (FIG. 8B).

From the TEM images of the MSU-γ prepared by the method of Example 16,it can be seen in FIG. 9 that the lath-shaped particles are uniform andapproximately 5 nm in thickness. Although the particles are consistentin shape, their arrangement is random. In our MSU-γ alumina the porosityarises from void spaces created through the aggregation of fundamentalparticles. The physical properties for the as-made MSU-S/B and calcinedMSU-γ aluminas prepared according to this example are provided in Table3.

TABLE 2 Experimental x-ray diffraction peaks for the atomically orderedalumina phases comprising the mesostructured networks of MSU-S/B andMSU-γ aluminas in comparison to the diffraction peaks reported in theliterature for boehmite and γ-alumina. The subscripts denote therelative intensities of the literature peaks. The experimental sampleswere prepared according to Example 16. MSU-B MSU-γ d₁₀₀ lit Å d₁₀₀ lit Åfor 2Θ for γ- 2Θ degrees d₁₀₀ Å boehmite degrees d₁₀₀ Å alumina 13.86.44 6.11₁₀₀ 19.6 4.53 4.56₄₀ 28.1 3.18 3.16₆₅ 32.5 2.76 2.80₂₀ 38.22.36 2.35₅₅ 37.1 2.42 2.39₈₀ 1.86₃₀ 39.5 2.28 2.28₅₀ 49.3 1.85 1.85₂₅46.3 1.96 1.98₁₀₀ 54.7 1.65 1.66₁₄ 1.52₃₀ 64.7 1.44 1.45₁₆ 67.0 1.401.40₁₀₀ 1.43₁₀ 71.9 1.31 1.31₁₆

Example 17

Example 17 illustrates that mesostructured MSU-S/B and mesostructuredMSU-γ alumina can be prepared from the same aluminum alkoxide and blockcopolymer surfactant described in Example 16, but at a lowerconcentration of aluminum and surfactant. The following molar ratioswere used:

1.0 mole Al(OCH(CH₃)CH₂CH₃)₃ 0.015 mole P84 19.8 mole water 0.97 mole2-butanolThat is, the amount of solvent used in this example is substantiallylarger in comparison to the amount in Example 16. Otherwise, theprocessing method was equivalent to Example 16. The physical propertiesfor the as-made MSU-S/B and calcined MSU-γ aluminas prepared accordingto Example 17 are provided in Table 3.

Examples 18 and 19

Other non-ionic surfactants can be used in the formation ofmesostructured MSU-S/B boehmite and MSU-γ alumina. Pluronic P123 is ablock copolymer surfactant with the formula (EO)₂₀(PO)₆₉(EO)₂₀. MacolLA12 surfactant has a 12-carbon hydrophobic backbone with a 12 unit PEOpolar head group. Both surfactants are commercially produced by BASF.

Examples 18 and 19 illustrate the preparation of mesostructured MSU-S/Bboehmite and MSU-γ alumina from an aluminum alkoxide precursor usingPluronic P123 and Macol LA12 surfactants, respectively, as structuredirectors. The surfactant was dissolved in a solution of water and2-butanol. To this surfactant solution, the aluminum alkoxide, dilutedin 2-butanol, was slowly added. Hydrolysis of the alkoxide was achievedupon this addition. This mixture was sealed in a glass reaction jar andallowed to age in an oven for 24 hours to afford the MSU-S/B product.Subjecting the mesostructured MSU-S/B to calcination at 500° C. for 4 hyielded mesostructured MSU-γ alumina. The physical properties of theproducts of this example are given in Table 3.

TABLE 3 Synthetic parameters and structural properties of as-madeMSU-S/B boehmite and calcined MSU-γ alumina. MSU-γ BJH PoreA1:Modifer:H₂O:ROH Hydrolysis MSU-S/B d₀₀₁/ S_(BET)/ Pore volume/Size/nm Example Precursor Surfactant molar ratio Temperature/° C.d₀₀₁/nm nm m²g⁻¹ cm³g⁻¹ Ads/Des 16 Al(O—C₄H₉)₃ P84 1:0.015:8.2:0.40 1006.5 6.9 306 1.15 18/9  17 Al(O—C₄H₉)₃ P84 1:0.015:19.8:0.97 100 — 5.6338 1.04 12/9  18 Al(O—C₄H₉)₃ P123 1:0.014:32.8:2.0 100 — 8.5 370 1.5120/13 19 Al(O—C₄H₉)₃ LA12 1:0.047:13.6:0.82 100 5.5 7.1 331 0.80 11/8 20 Al(O—C₄H₉)₃ none 1:0.0:19.8:0.97 100 — 7.9 259 0.47 6/6 Thecompositions of the non-ionic PEO surfactants are as follows: P84,(EO)₁₉(PO)₄₃(EO)₁₉; P123, (EO)₂₀(PO)₆₉(EO)₂₀; LAl2, C₁₂H₂₅(EO)₁₂. Thealcohol used in each example (ROH) was 2-butanol.

Example 20

This example discloses the formation of a mesostructured boehmite phase,denoted MSU-B, from aluminum sec-butoxide, Al(OCH(CH₃)CH₂CH₃)₃ in theabsence of surfactant, and the subsequent conversion of the MSU-B phaseto MSU-γ through thermal dehydration.

To obtain MSU-B boehmite in the absence of surfactant, aluminumsec-butoxide was hydrolyzed according to the method of Example 16,except that the surfactant was omitted from the mixture. The alkoxideand 2-butanol were mixed together until homogenous. To this mixture,water was slowly added with gentle stirring until thorough mixing andcomplete hydrolysis was achieved. Following hydrolysis, the mixture wassealed in a glass jar and placed in an oven for 24 hr. The boehmiteproduct was converted to MSU-γ following the calcination profiledescribed in Example 16.

The low angle and wide angle powder x-ray diffraction patterns of theMSU-γ alumina prepared in the absence of surfactant are shown in FIGS.10A and 10B, respectively. The relevant textural properties are reportedin Table 3.

Example 21

This illustrates the formation of a mesostructured transitiondelta-alumina, denoted MSU-δ alumina, prepared by the direct calcinationof an MSU-S/B precursor. This precursor was synthesized in a mannersimilar to the experimental procedure as described in Examples 18 and19. However, in the present example, the alcohol used in the surfactantsolution was ethanol instead of 2-butanol. The molar ratios aresummarized in Table 3. To obtain the MSU-δ alumina, the MSU-S/Bprecursor was heated at 2° C./min to 800° C. and held constant at thistemperature for 2 hours. Powder XRD patterns show a low angle peakcorresponding to a d-spacing of 6.1 nm indicative of a mesophase anddiffraction peaks assignable to δ-alumina in the high angle region(JCPDS Card#4-877). This product has a pore volume of 1.01 cc/g based onthe filling of pores at partial pressures in the range 0.80-0.95. Thepore size distribution determined from the adsorption isotherm wascentered near 17 nm. The BET surface area was 247 m²/g. In comparison,the surface area of a transition alumina prepared through dehydration ofaluminum hydroxides at temperatures near 800° C. is typically less than100 m²/g and the pore volumes are typically about 0.2 cc/g.

Examples 22-23

These examples illustrate the preparation of a mesostructured boehmite(denoted MSU-B) from a MSU-S/B surfactant/boehmite precursor. Thismaterial was prepared in two different manners. Example 22 employs thehydrolysis of aluminum sec-butoxide in the presence of a long-chainprimary amine, namely dodecylamine (DDA), as a structure director. DDAwas dissolved in water and ethanol at room temperature and stirred untila clear solution resulted. To this solution, a specified amount ofalkoxide was added. The molar ratios used were as follows:

1.0 mole Al(OCH(CH₃)CH₂CH₃)₃ 0.2 mole dodecylamine 3.5 mole ethanol 97.2mole waterThis solution was allowed to stir at room temperature for 20 hours. Theas-made product was centrifuged, washed with water, and dried at 50° C.for 4 hr. To obtain the surfactant free mesostructured product, thesample was subjected to low temperature calcination. The sample washeated at 2° C./min to 300° C. and held there for 6 hr. At thistemperature, the DDA was liberated without the concomitant conversion ofboehmite to γ-alumina. In addition to a low angle peak at 2θ of 1.56indicative a mesostructure, the boehmite phase was retained at thiscalcination temperature. The nitrogen isotherm showed filling of poresat partial pressures of 0.6-0.9 corresponding to an average pore size of5.8 nm as judged by the BJH pore size distribution. The surface area ofthis MSU-B was 361 m²/g.

Example 23 illustrates another approach to obtaining a mesostructuredMSU-B based on the direct hydrolysis of an aluminum alkoxide without theaid of a structure-directing surfactant. In this case, an amount of thealkoxide was hydrolyzed with 3 molar equivalents of water and stirreduntil the alkoxide was completely reacted. Aluminum sec butoxide waspoured into a glass jar. To this, 3 molar equivalents of water wereadded slowly with gentle stirring by spatula. Hydrolysis of the alkoxidewas achieved upon contact. After mixing until homogeneous, the samplewas allowed to air dry. Characterization by powder XRD revealed peaks inthe wide angle region assignable to boehmite. No low angle XRD peakswere observed, suggesting that the pore to pore correlation peak was toolarge to be observed (>18.0 nm). Nitrogen adsorption yielded an isothermindicative of pore filling over a large range of partial pressures. Theaverage BJH pore size of this MSU-B sample was 6 nm. A large pore volumeand BET surface area was also observed, 1.28 cc/g and 549 m²/g,respectively.

This sample could also be calcined to yield a large pore size, largepore volume, high surface area γ-alumina. The γ-Al₂O₃ formed uponheating at 500° C. for 4 hours (2° C./min) had a peak in the low angleXRD pattern corresponding to a d-spacing of 4.6 nm. From nitrogenadsorption-desorption analysis, a pore volume of 1.25 cc/g and a BETsurface area of 410 m²/g was observed. BJH pore size distributions werecentered at 9.0 nm (Ads) and 8.0 nm (Des).

It is intended that the foregoing description be only illustrative ofthe present invention and that the present invention be limited only bythe hereinafter appended claims.

1. A process for the preparation of a mesostructured, non-amorphous,crystalline transition alumina composition which exhibits: (i) at leastone low angle x-ray diffraction line corresponding to a lattice spacingof at least 2.0 nm; and (ii) multiple wide angle x-ray diffraction linesbetween 10 and 80 degrees 2⊖ with CuKα radiation where λ is 0.1541 nmcorresponding to an ordered oxygen atom lattice with aluminum ininterstitial positions within the lattice; wherein the surface area isat least 200 m²/g; wherein the pore volume is at least 0.40 cm³/g; whichprocess comprises: heating a mesostructured, non-amorphous, crystallinehydrated alumina composition exhibiting: (i) at least one low anglex-ray diffraction line corresponding to a lattice spacing of at least2.0 nm; and (ii) multiple wide angle x-ray diffraction lines between 10and 80 degrees 2⊖ with Cukα radiation wherein λ is 0.1541 nm,corresponding to an ordered lattice comprised of oxygen atoms andhydroxide groups with aluminum in interstitial positions within thelattice to a temperature in the range 400 to about 900° C. for a periodof time to cause dehydration of the hydrated alumina and the formationof the mesostructured form of the non-amorphous, crystalline transitionalumina.
 2. The process of claim 1 wherein the transition alumina isselected from the group consisting of gamma, delta, theta, eta, chi, andrho alumina and mixtures thereof.
 3. A process for the formation of amesostructured, non-amorphous, crystalline transition aluminacomposition: wherein the composition exhibits: (i) at least one lowangle x-ray diffraction line corresponding to a lattice spacing of atleast 2.0 nm; and (ii) multiple wide angle x-ray diffraction linesbetween 10 and 80 degrees 2⊖ with CuKα radiation where λ is 0.1541 nm,corresponding to an ordered oxygen atom lattice with aluminum ininterstitial positions within the lattice; wherein the surface area isat least 200 m²/g; and wherein the pore volume is at least 0.40 cm³/g,which process comprises: heating a mesostructured, non-amorphous,crystalline hydrated alumina and organic modifier composite composition,wherein the composition exhibits: (i) at least one low angle x-raydiffraction line corresponding to a lattice spacing of at least 2.0 nm;and (ii) multiple wide angle x-ray diffraction lines between 10 and 80degrees 2⊖ corresponding to an ordered lattice comprised of oxygen atomsand hydroxide groups with aluminum in interstitial positions within thelattice; to a temperature in the range 400 to about 900° C. for a periodof time to cause: (i) removal of the organic modifier component, (ii)dehydration of the hydrated alumina component, and (iii) the formationof the mesostructured form of the non-amorphous, crystalline transitionalumina which is not amorphous.
 4. The process of claim 3 wherein thetransition alumina is selected from the group consisting of gamma,delta, theta, eta, chi, and rho alumina and mixtures thereof.
 5. Theprocess of claim 3 wherein the organic modifier is a non-ionicsurfactant.
 6. The process of claim 5 wherein the surfactant is selectedfrom the group consisting of a polyethylene oxide block co-polymer, analkylene amine; an alkylene polyamine, and a polypropylene oxide amine,and polypropylene oxide polyamine and mixtures thereof.
 7. The processof claim 1 wherein the mesostructured crystalline hydrated aluminacomposition further comprises an organic modifier.
 8. The process ofclaim 7 wherein the organic modifier comprises a surfactant.
 9. Theprocess of claim 8 wherein the surfactant comprises a non-ionicsurfactant organic modifier.
 10. The process of claim 9 wherein thenon-ionic surfactant organic modifier is selected from the groupconsisting of a polyethylene oxide block co-polymer, an alkylene amine;an alkylene polyamine, a polypropylene oxide amine, polypropylene oxidepolyamines and mixtures thereof.